US20090068430A1 - Wood-fibre heat-insulating material and method for the production thereof - Google Patents

Wood-fibre heat-insulating material and method for the production thereof Download PDF

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Publication number
US20090068430A1
US20090068430A1 US12/248,425 US24842508A US2009068430A1 US 20090068430 A1 US20090068430 A1 US 20090068430A1 US 24842508 A US24842508 A US 24842508A US 2009068430 A1 US2009068430 A1 US 2009068430A1
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heat
insulating material
biologically degradable
less
property
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English (en)
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Matthias Troger
Michael Muller
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Homatherm AG
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Homatherm AG
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Publication of US20090068430A1 publication Critical patent/US20090068430A1/en
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/88Insulating elements for both heat and sound
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/04Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425Cellulose series
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4266Natural fibres not provided for in group D04H1/425
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5418Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00Other non-woven fabrics
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H15/00Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution
    • D21H15/02Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution characterised by configuration
    • D21H15/10Composite fibres
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/34Ignifugeants
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30Multi-ply
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30Multi-ply
    • D21H27/42Multi-ply comprising dry-laid paper
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742Use of special materials; Materials having special structures or shape
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742Use of special materials; Materials having special structures or shape
    • E04B2001/745Vegetal products, e.g. plant stems, barks
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742Use of special materials; Materials having special structures or shape
    • E04B2001/746Recycled materials, e.g. made of used tires, bumpers or newspapers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02ATECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00Adapting or protecting infrastructure or their operation
    • Y02A30/24Structural elements or technologies for improving thermal insulation
    • Y02A30/244Structural elements or technologies for improving thermal insulation using natural or recycled building materials, e.g. straw, wool, clay or used tires
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/24992Density or compression of components
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/26Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/268Monolayer with structurally defined element
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2631Coating or impregnation provides heat or fire protection
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/50FELT FABRIC
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/50FELT FABRIC
    • Y10T442/59At least three layers

Definitions

  • the invention relates to a biologically degradable heat-insulating material which contains, inter alia, cellulose and/or wood fibres and bico-fibres, that is two-component fibres as binders.
  • the present invention further relates to a wood-fibre heat-insulating material which exhibits a heat-insulating property, a thermal stress-relieving property, a sound-damping and fire-retarding property, a fire-resistance property, a sound-damping property, preferably an ant-repelling property, a moisture regulating property, an environmental protection property and detoxification properties.
  • the invention further relates to a method for producing a heat-insulating material by the combined application of a dry method and a semidry method.
  • Wood fibre boards comprise a soft fibre board (insulating board) having a density of less than 350 kg/cm 3 and produced by a wet process which uses sludge in which wood fibres, binders and size are dispersed in water, as in paper manufacture, a medium-density wood fibre board (MDF) which is produced by spraying an aqueous solution containing wood fibres, a melamine resin binder and a water-repellent agent to be applied with adhesive bonding strength, and by drying the solution by a dry method using a heating press, and furthermore a hard fibre board (hard board) having a density of 800 kg/m 3 or more which is press-formed by heating at high pressure. These boards are used differently in the household as construction materials and furnishing materials.
  • MDF medium-density wood fibre board
  • the unexamined Japanese Patent Publication No. 2001-334510 describes a cost-down technology whereby MDF boards having a low density are achieved whilst saving energy by forming a mixture containing wood fibres and a thermoplastic resin binder into a fleece and thermally fixing the binder at a temperature higher than its softening point.
  • the unexamined Japanese Patent Publication No. 2002-337116 describes a process in which MDF is dipped in an aqueous solution in which polyethylene glycol, a triazole ant repellent and ammonium phosphate in a phenol resin form a mixture in order to make the MDF flame-retardant and insect-proof.
  • the unexamined Japanese Patent Publication No. 2003-311717 describes a recycling method by which means recycled material having a density of 50 to 250 kg/m 3 and a fineness of 0.01 to 20 mm, obtained by crushing a used wood fibre board, is mixed with the raw material of the MDF.
  • the unexamined Japanese Patent Publication No. 2006-289769 describes a method for producing MDF having a weight per shot of 400 to 2500 g/m 2 and a thickness of 2 to 50 mm by laminating a nonwoven obtained by mixing the fibre polylactate with cellulose fibre having an average fibre length of 5 to 100 mm.
  • the aforesaid improvement technologies pertain to the improvement technologies of an insulating board which is produced by a wet process or to those of MDF produced by a dry process, and each of these technologies corresponds to the thermal insulation, non-flammability, insect resistance, energy saving, cost reduction and the measures for recyclability but the present situation is such that no forming methods and manufacturing methods have been achieved with this, whereby the problems can be comprehensively resolved.
  • the present invention provides for properties such as elasticity, mechanical strength, sound damping, flame retardance and fire resistance as well as ant repellence such as have not been found previously in an insulating board produced by a wet process, even though the density range is similar to that of an insulating board produced by the wet process and the semidry process, and it improves the thermal insulation, moisture regulating property and the measure against unhealthy living and a diseased environment.
  • the flame-retardant and fire-resistant properties its performance features are equivalent to or more than equivalent to a glass wool heat-insulating element and a rock wool heating insulating element and likewise with regard to the thermal insulation, a thermal stress-relieving property which delays heat transfer in an unstable state, which is not observed in a foam heat-insulating element, and a high thermal insulation are made possible by an airtight adiabatic construction.
  • used heat insulating material according to the present invention is used as fertilizer fleece in agriculture and forestry and contributes to the activation of forests and detoxification of the environment and forms a measure against global warming.
  • a felt-like heat insulating material according to the present invention can be subjected to a secondary utilisation by a moistening form pressing and hot forming and, when used as an ecological interior material for automobiles, contributes to the development of a new field.
  • the present invention comprehensively solves the aforesaid problems by means of a heat-insulating material having a density of 300 kg/m 3 or less, which is the same as that of an insulating board produced by a wet method, wherein a mixture produced by a wet method and a semiwet method is used as the main material, said mixture comprising a wood fibre having an average fibre diameter of 1 mm or less and an average fibre length of 20 mm or less and a biologically degradable binder which swells in hot water and fixes due to heat, having a fineness of 10 dtex and a fibre length of 20 mm or less.
  • the heat insulating material produced by the method of manufacture has a low density and elasticity and as result of the airtight adiabatic construction which uses a thermal stress-relieving property due to a low thermal conductivity and a high thermal capacity and elasticity, provides high thermal insulation and sound damping such as has not been found previously in inorganic staple fibre heat-insulating material such as glass wool or foam heat-insulating material such as extruded and expanded polystyrene.
  • the wood fibre which is treated with a flame-retardant, ant-repellent agent which is doubled with a fertilizer component furthermore forms a carbonised heat-insulating layer against ignition by fire and heat on the surface of the heat-insulating material and is self-extinguishing, a wall element combined with a plasterboard and the like shows excellent fire-retardant and fire-resistant properties.
  • the raw materials of which the heat-insulating material is composed are biologically degradable and since the flameproof ant-repellent agent contains the three fertilizer elements for plant cultivation, they can be used, including the waste from used insulating materials, as fertilizer material without any loss due to transplanting. They also exhibit an environmental cleaning function which contributes to accelerated growth of seeds activation of forests, reduction of CO2 and prevention of global warming.
  • FIG. 1 is a flow chart of the preferred method of the invention.
  • Wood fibre forming the heat-insulating material according to the invention is obtained by treatment of thin timbers such as conifers, for example, silver fir, Asibrica, Japanese larch, cedar and spruce and broad-leaved trees such as beech, maple and sawtooth oak; wood chips from old timbers and ground tough bark of bamboo, hemp and the like with flame-retardant ant-repellent agents, doubled with a fertiliser component, and fibrillation thereof.
  • thin timbers such as conifers, for example, silver fir, Asibrica, Japanese larch, cedar and spruce and broad-leaved trees such as beech, maple and sawtooth oak; wood chips from old timbers and ground tough bark of bamboo, hemp and the like with flame-retardant ant-repellent agents, doubled with a fertiliser component, and fibrillation thereof.
  • the wood chips and ground products are obtained by cutting timbers into the form of thin pieces having a length of 10 to 30 mm and a width of 5 to 15 mm and treatment thereof with a refining agent described subsequently.
  • the wood chips and ground products treated with a flame-retardant ant-repellent agent are treated with steam and softened by steam or the like, and then shredded by a refiner so that they have an average fibre diameter of 1 mm or less and an average fibre length of 20 mm or less, and further processed into wood fibres.
  • the reason for an average fibre diameter of 1 mm or less is to ensure elasticity of the heat-insulating material obtained and to reduce its thermal conductivity.
  • the reason for an average fibre length of 20 mm or less is to suppress granulation of adjacent fibres and the production of fluffs during a mixing step with a fibrous binder described subsequently in a dry process and the uniform mixing thereof by dispersion. Uniform dispersion is appropriate in a range of 10 to 300 L/D (fibre length/fibre diameter) and the fibre length is preferably 20 mm or less.
  • the flame-retarding ant-repellent agent doubled with a fertiliser component which is the main component of the heat-insulating material of the present invention is mixed in a state in which a dip treatment of the wood fibre is carried out.
  • the flame-retarding ant-repellent agent doubled with a fertiliser component gives the heat-insulating material according to the present invention a flame retardance and non-flammability and a composite element with a plaster board and the like, a fire-retardant and fire-resistant property and it provides for an ant-repelling property as a measure against termite erosion.
  • the flame-retarding ant-repellent agent is doubled with a fertiliser component which can be used as a fertiliser fleece and as matting for the cultivation of seedlings in agriculture and contains used heat insulating material.
  • the flame-retarding ant-repellent agent doubled with a fertiliser component is a mixture of a boron compound and a phosphorus compound and especially contains boric acid, borax, borosilicate, ammonium polyphosphate, ammonium dihydrogen phosphate, magnesium polyphosphate, potassium polyphosphate, sodium hypophosphite and sodium sulphite as solution aid and potassium carbonate and magnesium chloride as fixing aid. If an immersion-adherent quantity for the wood fibre is 2 wt.
  • the flame-retardant effect and the ant-repellent effect are inadequate and at 30 wt. % or more, a saturation effect occurs, which results in increased expense which is why 2-30 wt. % is considered to be appropriate.
  • the biologically degradable binder forming the main component of the heat-insulating material according to the invention is a natural and synthetic binder and comprises a mixture of hot-water-soluble adhesive binder which is suitable for a wet method and for a semidry method and a hydrophobic thermally fixing binder and is restricted to a biologically degradable binder in fibre form.
  • the natural and the synthetic hot-water-soluble binder contains a natural starch, cellulose derivative and chitosan and the hot-water-soluble binder contains ideally saponified polyvinyl alcohol, a silicon-containing polyvinyl alcohol and the like. It corresponds to a binder that is fibre-supported, for example, by wood fibres or a fibrous binder.
  • the synthetic hydrophobic thermally fixing binder contains polycaprolactam polyamide, polylactic acid, aliphatic polyester resins such as polybutylene succinate, polybutylene succinate adipate and a biologically degradable polyethylene polypropylene composite resin that is fibrous.
  • the fibrous binder is restricted to a fibre-supported type of binder, having a fineness of 10 dtex or less and a fibre length of 20 mm of less, or to a fibrous binder in order to ensure homogeneous mixing of the raw material by dispersion, the degree of fineness of the mixture and the property of a flaky deposit and a distribution in the dry method and the semidry method which are the forming methods of the present invention.
  • the main component of the composition according to the present invention comprise the wood fibres, the flame-retardant ant-repellent, doubled with a fertilizer component and the biologically degradable hot-water soluble and thermally fixing fibrous binder which has been explained previously.
  • a suitable mixture can be produced from environmentally friendly additives such a water-repellent fluorochemical agent, a water-repellent silicone oil agent, alkyl ketene dimer as bonding agent, an anti-bacterial agent in which antibacterial substances such as copper and zinc [using] calcium phosphate as carrier and fungicides such as hinokitiol and chitosan as further additives.
  • a fleece and a light-weight building board made of the heat-insulating material according to the invention can be produced by a method in which the dry method and semidry method described hereinafter are used in combination, wherein this fleece and this light-weight building board differ from the insulating board produced by a wet method and by the MDF board produced by a dry method.
  • the method of manufacture according to the present invention is shown in the flow diagram in FIG. 1 .
  • Wood chips 1 having a length of 15 to 25 mm, a width of 5 to 10 mm and a thickness of 2 to 5 mm, obtained by peeling the outer tree bark of thin timbers and old timbers of conifers and broad-leaved trees which are dipped at 6 in an aqueous solution or suspension containing a boron compound and a phosphorus compound at a normal temperature of up to 80° C. for a duration of 2 to 24 hours, are treated with steam at a vapour pressure of 0.5 to 1 MPa for a duration of 5 to 20 minutes and at 8 are successively defibrillated using a single- or two-disk refiner.
  • the average fibre diameter, the average fibre length and the output rate of the wood fibres can be controlled by varying the rotational speed of the refiner and by varying the distance between the fixed blades and the rotating blades.
  • a first binder 2 that is biologically degradable can optionally be added to the wood chips 1 .
  • the wood fibre treated at 7 with a flame-retardant ant-repellent doubled with fertilizer component, which is produced in a refining step, is temporarily packaged by compressing as a flock bale which is moistened if necessary at 9 with a moisture content of 15 wt. % or it is fed to a drum screen in a next step for mixing by dispersion.
  • the drum screen which mixes the wood fibres 3 , the biologically degradable binder 5 and other additives 4 is a conical trapezoidal rotator having a metallic mesh network at its outer periphery.
  • the supplied raw materials of the heat-insulating material are agitated continuously and mixed in the direction of an outlet opening at 10 and dispensed due to the difference between the peripheral velocities of the feed opening on the smaller diameter side and the outlet opening on the larger diameter side.
  • the product which has been comminuted in this step is separated from the raw materials and removed to the outer periphery by the metal network.
  • the raw materials of the heat-insulating material which have been mixed and dispersed by the drum screen are transported by pneumatic conveyance at 11 into a chamber for collecting the flaky deposit, which has a mesh strip provided with a suction device on the back and these materials are collected by a dry method in order to be formed into thick fleeces.
  • These fleeces are then transferred onto a continuous conveyor belt and then brought into a state having approximately fixed thickness and density by form pressing at 12 and then a binder 5 comprising a fibrous hot-water soluble binder is made to swell by moisture to bind the fibres to one another and to give the fleeces a shape stability property and elasticity.
  • the density of the upper and lower layer of the fleece is increased to more than the density of an intermediate layer by carrying out a further high-pressure drying and a three-layer structure having different densities is formed.
  • the fibrous binder 5 is then thermally fixed whilst it is subjected to a press forming with a mobile conveyer by the drying method and the fleece acquires the form of the end product having strength and elasticity.
  • the fibrous binder 5 is provided, for example, by bico fibres.
  • the fleece and the board produced from the heat-insulating material by the dry method and the semidry method have a good appearance, are uniform and possess strength in a thickness direction; they have a heat-insulating property (low thermal conductivity), are flame-retardant and fire-resistant, have an ant-repelling effect, are sound-damping, moisture-regulating, VOC-free and possess the properties of a fertilizer material.
  • the felt from the heat-insulating material according to the invention can be produced by the energy-saving dry method described subsequently.
  • the felt of the present invention is a felt obtained by manufacturing the paper by a dry method from a mixture containing the previously described composition, by forming a felt having a thickness of 2 to 10 mm and a density of 200 to 300 kg/m 3 by the aforesaid wet adhesion and thermally fixing adhesion, by laminating a commercially available biologically degradable nonwoven onto one or both sides of the felt and by needling, wherein the felt acquires a fixed length or is rolled up.
  • the felt can be produced by a similar method as in paper manufacturing but for reasons of saving energy and saving costs during manufacture, it is advantageous to produce the paper by the dry method and the semidry method.
  • a felt having a thickness of 2 to 10 mm can be produced by a circular network, long network or funnel forming system using an aqueous sludge in which the aforesaid raw materials of the heat-insulating material are distributed with a concentration of 1 to 5 wt. %.
  • the raw materials of the heat-insulating material are dispersed by the air flow of the air laying system which has been developed by M&J Fibertech Co. in Denmark, and Danweb Co and can be formed into a felt having a thickness of 2 to 10 mm.
  • the felt is preliminarily dried in the wet method but the felt is adjusted to a moisture content of about 15 wt. % by moistening with steam in the dry method.
  • the fibres are adhesively bonded to one another by the wet adhesion and by thermally fixing adhesion of the fibrous binder of the felt in order to form a soft-elastic felt similar to that in the dry method and in the semidry method.
  • a commercially available fibre material having a weight per shot of 20 to 100 g/m 2 (e.g. TERRAMAC from Unitika Ltd.) is laminated onto one or both sides of the felt, needled and finally processed to a felt which in practice has a strength such that it can be rolled up.
  • the finished heat-insulating material 22 can finally be formed as board which ultimately consists of a fleece which can be laid with felt on one or the other end side.
  • the felt can be formed from the initial materials wood fibres 14 , biologically degradable binder 15 and optionally additives which are processed in the dry method at 16 and further processed at 17 to give felt.
  • the previously formed fleece is combined with the formed felt wherein a moistening and hot forming by the semidry method can take place in a first step 18 and a hot forming by the dry method in a second step 19 .
  • a moisture regulating and curing step can be carried out at 20 and optionally a step involving cutting and final processing to form the thermal product 22 can be provided at 21 .
  • the bark of dried, thin timbers such as Asibrica, Japanese larch and cedar was removed and wood chips having a length of about 20 mm, a width of about 15 mm and a thickness of 2 mm were dipped in the hot water solutions for a duration of 24 hours:
  • the treated wood chips were damped at a steam pressure of 1 MPa for a duration of 10 minutes, fed into a double-disk refiner and fibrillated at a rotational speed of 800 rpm and a spacing of 2 mm, wherein however a powdery binder is added at this time if this is necessary (described subsequently).
  • the moisture treatment was then carried out to produce a wood fibre which is treated with a flame-retardant ant repellent doubled with a fertilizer component and which has an average fibre diameter of 0.2 mm and a fibre length of 20 mm. Codes which are given in the following Table 1 were provided for the wood fibres obtained from the different trees and using the different treatment solutions.
  • Poval resin powder having an ideal degree of saponification (POVAL V-20) manufactured by JAPAN VAM & POVAL Co. Ltd.) was mixed with the wood fibres (A- 1 and A- 2 ) with a fraction of 10 wt. % in powder form to produce a powdery binder (1) which was combined with the wood fibres coated with Poval resin.
  • VINYLON VPB made by Kuraray Co., Ltd
  • ES FIBER VISION biologically degradable thermally fixing polyolefin composite fibre
  • the raw materials distributed homogenously due to the mixing were conveyed by pneumatic conveyance to a collection chamber (a device for flock deposition, comprising a continuously moving continuous mesh network conveyer, which is fitted with a rear suction box) and were then collected and laminated to form homogeneous and thick fleeces.
  • the thick fleeces were transported to a reciprocating double conveyor of a continuously moving conveyor plate and arranged there, and a form pressing of the fleeces to an approximately solid thickness was carried out by the dry method which includes the step of changing the distance between the reciprocating conveyors.
  • the fleece was transported forwards and backwards to a divided zone on the double conveyor, the fibrous binders were laminated wet with the wood fibres in a temperature range of 70 to 100° C. by the semidry method by which steam was expelled from the reciprocating conveyors, and formed manageable primary fleeces were produced.
  • the formed primary fleeces were then finish-processed to given heat-insulating materials having suitable strength and elasticity whereby the fleeces were heated by the dry method whereby a hot air flow was expelled from the reciprocating conveyor whilst they were compressed to their final thickness in a subdivided zone as in the previous step and whereby the fibrous binders were thermally fixed in a temperature range of 100 to 150° C.
  • the mixture formation ratio, the thickness and density of the wood fibres, the flame-retardant ant-repellent agent and the fibrous binders were varied in the aforesaid methods in order to produce the heat-insulating materials according to Table 2.
  • the thermal conductivity of the heat-insulating material from Table 2 was measured in each case in accordance with the board direct method according to JIS-A-1412 and the specific thermal capacity was measured by Kohlrausch liquid calorimetry.
  • the elastic restoring properties of the heat-insulating material were evaluated according to elasticity ((A): good, (B): normal and (C): poor recovery)) and according to the restoring rate (%). The results obtained are given in Table 3.
  • the heat-insulating materials manufactured for the tests showed a good result with regard to thermal insulation and elasticity according to Table 3.
  • Samples Nos. 1 and 2 from Example 1 were cut to a size of 10 cm ⁇ 10 cm ⁇ 2 cm and four sides and their base was coated with an aluminium foil to prepare sample bodies.
  • the flame-retarding properties of the sample bodies were evaluated in accordance with CCM (cone calorimetry) with reference to the public bulletin No. 9, Article 2 of the Building Standards Law and the result was 5.2 MJ/10 min and 6.5 MJ/20 min and they were certified as quasi-flammable and flammable.
  • the thermal conductivity which shows the degree of heat transfer under a stable state (environment in which the external temperature does not change) of the heat-insulating material manufactured for the tests is the same as that of the glass wool heat-insulating material but the thermal diffusivity which shows the heat transfer under an unstable state (environment in which the external temperature changes) is only 1 ⁇ 6 and the heat transfer in an environment with varying external temperature is reduced substantially.
  • the heat-insulating material manufactured for the tests has a good sound damping effect in a low frequency range, which shows elasticity.
  • the two layers of the heat-insulating material No. 4 from Example 1, manufactured for the tests were inserted in a slightly large dimension between two wooden stamps of a test frame with wood axes having a body difference of 100 ⁇ 100 mm, a post of 100 ⁇ 100 mm and a wooden stamp of 100 ⁇ 50 mm and were adhesively bonded with a heat expansion board (BLGR) manufactured by MARUSAN PAPER MFG. CO., LTD.) mixed with graphite having a thickness of 2 mm, and the stamp spacing was 455 mm, and the fire resistance effect and the sound damping effect of a partition wall clad with plasterboard having a thickness of 12.5 mm on both sides was evaluated.
  • BLGR heat expansion board
  • the fire resistance effect was determined by carrying out the fire resistance test in accordance with Public Bulletin No. 1358 of the Building Ministry with reference to the standard fire curve ISO 834. The result was an average temperature of 132° C. and a maximum temperature of 145° C. on the non-heated front side and this was approved as semi-fire-resistant for 45 minutes.
  • the heat-insulating materials Nos. 4 , 6 and 8 from Example 1 manufactured for the tests were cut to 100 ⁇ 100 mm and had four sides and their back faces were sealed with an aluminium adhesive strip. They were dried for 24 hours at 45° C. and then cured at 25° C. and 50% RH for a duration of 72 hours in order to measure the moisture-absorbing and moisture-releasing effect.
  • the measurement conditions for the moisture-absorbing and the moisture-releasing effect comprised moisture absorption at 25° C. and 90% RH for 24 hours and then moisture release at 25° C. and 50% RH over 24 hours, which corresponded to one cycle. Three cycles were carried out. The moisture absorption and the moisture release were measured and the result is shown in Table 6.
  • Table 6 shows that the materials absorb and release moisture according to the ambient temperature and that they exhibit a moisture regulating effect which is the same as or higher than that of a spruce material.
  • the heat-insulating material No. 4 from Example 1 having a thickness of 50 mm was provided by insertion between support beams on a floor (A), and wherein to give realism, a 50 mm thick floor covering material of wood under high tension was provided on the surface of the exposed support beam so that the gap between the top side of the support beam and the heat-insulating material was an air layer and in addition, a 12.5 mm thick plasterboard was provided as a layer on the underface of the support beam to create a floor (B). The floor was acted upon by a bag machine and the damped impact noise was measured in a corresponding lower room.
  • the measurement method was carried out in accordance with JIS A-1418 (measurement of the impact sound level in a building).
  • the impact sound level of the floor (B) was 50 dB and it showed a good impact sound damping effect whereas the impact sound level of the floor (A) was 71 dB.
  • the ant repellent effect was determined by reference to the weight reduction rate ((A): 5% or less, (B): 5 to 10% and (C): 10% or more) and by visual observation ((A): good; (B): some damage was determined but this was slight, and (C) more severe damage was determined).
  • the result is shown in Table 7.
  • Heat-insulating material Weight reduction Visual observation Heat-insulating (B) (B) material according to the invention Glass wool heat- (B) (B) insulating material Extruded foamed (C) (C) polystyrene heat- insulating material Cedar (C) (C)
  • the heat-insulating material manufactured for the tests did not show any 100% ant-repellent effect different to the glass wool heat-insulating material but showed a comparable ant-repellent effect. Consequently it was found that an effective measure for repelling ants is possible due to a combination with foamed glass having an ant-repelling effect and by partial coating with an ant repellent.
  • the heat insulating construction was implemented in four detached houses (of the order of magnitude of about 200 m 2 and two storeys) with timber framing in Date City and Obihiro City in Hokkaido, using the heat-insulating material No. 4 from Example 1 manufactured for the tests and having a density of 55 kg/m 3 and a commercially available glass wool heat-insulating material having a density of 16 kg/m 3 and a thickness of 50 to 10 mm.
  • the properties as construction material processingability, building-in rate and treatment of waste material
  • the properties as residential material heat insulation, sound damping and measure for healthy living
  • Table 8 shows that the heat-insulating material manufactured for the tests is superior to the glass wool heat-insulating material both with regard to the property as a construction material and with regard to the property as a residential material.
  • the fleeces A and B obtained were transferred to a double conveyor in the same way as in Example 1 and were compressed to 3 mm and wet adhesion and thermal fixing were carried out by steam moistening and heating with hot air.
  • a commercially available nonwoven (TERRAMAC 50 g/m 2 , made by Unitika Ltd.) was laminated and needling was carried out to form felts A and B.
  • the forming and processing test of an uneven shape and a curved surface shape was carried out for felt A of Example 10 in order to confirm the adaptability as a formable material having heat and sound-damping properties, for example, as a material for the inner roof of a motor vehicle and as a floor insulator.
  • the felt can be formed by wet adhesion and thermal fixing at a temperature of 150° C. and a pressing pressure of 1 to 10 Kg/cm 2 and the possibility for processing to form a three-dimensional structure and the press formability was confirmed.
  • Fleece No. 4 from Example 1 contains N, P, K and B fertiliser components and no polluting substances in accordance with DIN 38409, EPA 610 and DIN-EN120 were detected.
  • the fleece was furthermore used as plant cultivation matting and a fertilizer fleece for seeds such as rice and wheat, for fruit and vegetable such as tomatoes, cucumbers and aubergines, root vegetables such as greater burdock and for potatoes. The plant growth and the harvest are good without continuous damage to the planting.
  • the fleece was naturally degraded into earth over two to three months and it was confirmed that no negative factor regarding the activity of soil micro-organisms is present.
  • the heat-insulating material according to the invention is obtained by producing a mixture containing fibrous materials by a dry method and a semidry method. It creates a product having good properties such as flat appearance, flexibility, elasticity, and manageability of fleeces, boards and felts having a low density of 40 to 300 kg/m 3 .
  • the wood fibre treated with the heat insulation exhibits a flame-retardant and fire-resistant property and an appropriate ant-repelling effect.
  • the heat-insulating material exhibits a good flame-retardant property and fire resistance not comparable to glass wool, is more effective than semi-fire-resistant as a composite element with a construction board and allows the development of a new type of fire-resistant and heat-insulating construction material since the surface of the heat-insulating material forms a carbonised heat-insulating layer even if it is exposed to fire and heat.
  • the sound-insulating effect is very high, particularly in the low frequency range.
  • the heat-insulating material according to the present invention is a natural material and is composed of biologically degradable materials, the heat-insulating material does not pollute the environment as a waste material even it is left behind and is doubled with fertilizer components; thus, it can be used as cultivation matting and fertilizer fleece and at the same time exhibits an effect for activating forests and thinned-out timbers, including an environmental cleaning effect.

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  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
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  • Dry Formation Of Fiberboard And The Like (AREA)
  • Building Environments (AREA)
US12/248,425 2007-09-10 2008-10-09 Wood-fibre heat-insulating material and method for the production thereof Abandoned US20090068430A1 (en)

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US8871053B2 (en) 2010-08-03 2014-10-28 International Paper Company Fire retardant treated fluff pulp web
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EP2511586A1 (de) 2011-04-14 2012-10-17 Saint-Gobain Isover Isolierendes Produkt
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WO2015125083A1 (en) * 2014-02-18 2015-08-27 Stora Enso Oyj Method for producing a foam-formed insulation material
US20170183869A1 (en) * 2014-04-11 2017-06-29 Bionic Alpha Ag Lightweight construction element, manufacturing method therefor, use of same, and lightweight panel and insulating material
CN105082315A (zh) * 2015-08-11 2015-11-25 阜阳祥云木业有限公司 一种装饰板材的加工工艺
EP3143870B1 (de) 2015-09-17 2017-08-09 SWISS KRONO Tec AG Holzfasermatte zur verwendung als pflanzensubstrat
EP3235370B1 (de) 2015-09-17 2018-06-20 SWISS KRONO Tec AG Holzfasermatte zur verwendung als pflanzensubstrat
EP3235370B2 (de) 2015-09-17 2022-06-01 SWISS KRONO Tec AG Holzfasermatte zur verwendung als pflanzensubstrat
US20210269225A1 (en) * 2018-06-28 2021-09-02 Illuminate Consulting, Llc Biotic material apparatus for thermally protecting and/or transporting temperature sensitive products
US11958677B2 (en) * 2018-06-28 2024-04-16 Illuminate Consulting, Llc Biotic material apparatus for thermally protecting and/or transporting temperature sensitive products
US20210171395A1 (en) * 2019-12-10 2021-06-10 Jaime Alonso Chavez Medina Light mineral organic insulation
WO2022175394A1 (en) 2021-02-17 2022-08-25 Aisti Corporation Oy Ultralow density fire-retardant fiber composite foam formed material, product and manufacturing method thereof

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EP2048295A3 (de) 2014-10-29
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CA2640904A1 (en) 2009-04-09
DE102007048422A1 (de) 2009-04-16

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